Rug and method of making the same



Feb. 26, 1929.

G. C. RASCH RUG AND METHOD OF MAKING THE Sm .l-iled Nov. 22; 1926 Patented Feb. 26, 1929.

1,703,636 PATENT OFFICE.

GUSTAVE O. RABCH, OF BURLINGTON, WISCONSIN, ASSIGNOR TO BURLINGTON 4 BLANKET COMPANY, 03' BURLINGTON, WISCONSIN, A CORPORATION OF WIS- OONSIN.

BUG AND METHOD OI MAKING THE SAME.

Application filed November 22, 1926. Serial No. 149,891.

This invention relates to rugs and method 1 of making the same, and the object of the invent-ion is to improve the construction and texture of rugs in the manner to be herein- 5 after described and claimed.

Referring to the drawings, which accompany this specification and form a part hereof, which drawings illustrate an embodiment of this invention, and on which drawings the same reference characters are used to designate the same parts wherever they may appear in each of the several views, Fig. 1 is a perspective view of a rug; Fig. 2 is a partial section, on a greatly enlarged scale, on the line 2-2, on Fig. 1, looking in the direction indicated by the arrows; and Fig. 3 is a section similar to Fig. 2, but on a smaller scale, and also showing component parts of the rug separated and illustrating the method of making the same.

Referring to the drawings, the reference numeral 1 designates a rug, which, as illustrated by the drawings, iscomposed of different layers of materials. The reference numera1 2 designates a stay for the bottom of the rug which may be of any suitable material. The drawings illustrate the stay 2 as composed of burlap which is a suitable material for the stay 2. The reference numeral 3designates a filling layer, or cushion, of loosely matted fibers, as distinguished from a felt. In making the rug, the rug is built up from the bottom by first needling the filling layer or cushion 3 after the filling layer or cushion 3 has been placed upon the stay 2. This first needling operation, which ma be performed by means of an ordinary nee lingmachine, not only needles the matted fibers composing the filling layer or cushion 3 together, but also needles, or anchors this filling layer 3 to the stay 2. The result of the first needling operation is illustrated at 9 in Figure 3 of the drawing. The filling layer 3 may be composed of comparatively cheap grades of wool with which animal hair or bristles or any suitable animal or vegetable fibers may be mixed. An upper stay 4 is then placed on top of the filling layer or cushion 3 and this upper stay 4 is treated with glue or sizin or any other suitable adhesive material. T is treatment of the upper stay 4 with an adhesive material may be readily and economically performed by running a suitable material, preferably a woven material, through a liquid bath of adhesive and squeezing out excess adhesive by a roll or rolls, for example to leave the stay sized with an adhesive, but moist for succeeding needling operations. An upper layer of loosely matted fibers, a bat of wool, for example, 5 is then placed on top of the upper stay 4 and the rug, as thus far completed, is subjected to another needling operation, while the upper stay 4 is still moist with the adhesive. The result of a second needling operation is illustrated at 10- in Figure 3 of the-06 drawing. This needling operation not only needles the fibers of the upper layer 5 together but carries fibers from the upper layer 5 down through the moist upper stay 4 and into the filling layer or cushlon 3. The needling, referred to, is usually performed in machines which have a large number of needles pointing downward and with barbs projecting from the needles and extending towards the points of the needles. This needling operation may be such that the needles and their lowermost barbs run entirely through the filling layer or cushion 3 and the bottom stay 2, or, if desired, the lowermost barbs of the needles, which are the mechanical means for catching and carrying fibers with them, may not be permitted to pass through the lower stay 2. A finishing layer 6, preferably of a nice grade of wool, may then be needled to the upper layer 5 and, preferably, this needling operation is performed while the upper stay 4 is still moist and the lower barbs of the needles are, preferably, forced through not only the upper layer 5 but also through the upper stay 4 while the upper stay 4 is still moist with the adhesive. The finishing layer 6 is provided, as a separate layer, to provide the rug with a surface of a better quality of material than that used for the filling layer or cushion 3 and the upper layer 5. The finishing layer 6 also provides an easy method for imparting designs or ornamentations to the top of the rug as will be readily understood from an inspection of Fig. 1 of the drawings which illustrates a rug with its body part 7 of 100 a substantially general uniform appearance with a contrasting border 8. Fig. of the drawings merely illustrates an example of or namentation of the top of the rug and the ornamentation is, of course, subject to practi- J05 cally an infinite number of variations. 2

By needling layers of a rug together with aninterposed sized stay, the needling operations being performed while the sized sta is still moist, a rug is produced in whi 110 under an sists in needling a parts are not. onl needled together. but

enough fibers are a so cemented together to shown by Fig. 3 of the drawings, is only ntended to emphasize the relationship of the parts of the rug to each other.

I have referred to my'mventlon as an mprovement in rugs and method of making the same for the reason that the completed fabric is used extensively for coverin s for floors and the like under the common an popular use of the term rug, but I wish it to be understood that I have used the term rug in a broad sense to designate a fabricated material-which may be used in any place and conditions for which it is suited. What claim is: 1. The process of making rugs, which conlayer of matted fibers through a stay, moistened with an adhesive, into another layer of matted fibers, while the adhesive on the stay is still moist. P

2. The process of making rugs which consists in needling a layer of matted fibers, imosing thereon a stay moistened with an adesive,'imposing on the stay another layer of loosely matted fibers,

tom stay, an adhesive impr and needling said stay, while still moist with the adhesive, into the first mentioned layer of matted fibers.

3. A rug composed of two layers of matted fibers with a stay impregnated with an adhesive thcrebetween, with the layers needled together through the stay and fibers of both layers cemented to the stay and to each other.

4; A rug composed of a bottom stay, a filling layer or cushion of loosely matted fibers needled together and anchored to said bottom stay, an adhesive impregnated stay and an upper layer of loosely matted fibers needled to ether and through said upper stay and to said filling layer or cushion with fibers of the filling layer or cushion and the upper layer cemented to said upper stay and to each other.

5. A rug com osed of a bottom stay, a filling layer or cus ion of loosely matted fibers needled together and anchored to said botated stay, an upper layer of loosely matte fibers needled together and through said upper stay and to said filling layer or cushion with fibers of the filling layer or cushion and the upper layer cemented to said upper stay and to each other, and a finishinglayer needled on top of the rug.

In witness whereof I hereto aifix my signature.

GUSTAViE C. RASCH. 

